Honeycomb Die Electrode Fabrication With AM and Pin Smoothing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for forming honeycomb extrusion dies with complex geometries, such as wire EDM, are impractical for creating patterns with non-linear features and require additional time, materials, and cost when using plunge EDM or ECM, which often result in defects and inefficiencies due to the need for specially configured electrodes.
Innovation Solution
An additive manufacturing method involving the layer-by-layer deposition of tungsten and copper powders, followed by laser fusion to create an interconnected network of tungsten infiltrated by copper, forming a base with a web defining a matrix of cellular openings, which can be used to produce electrodes for forming honeycomb extrusion dies with varied geometries efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If wire EDM is used to form honeycomb extrusion dies, then linear patterns can be formed, but complex non-linear geometries cannot be formed
Solution Approach 1:
The patent replaces the mechanical wire cutting system with an electrical discharge machining system that uses electrical energy to erode material. This substitution enables the formation of complex three-dimensional geometries including non-linear patterns, curved surfaces, and internal features that cannot be achieved with linear wire cutting, while maintaining manufacturing feasibility through automated EDM processes
2Adaptability or versatility
If plunge EDM or ECM is used to form extrusion dies with complex patterns, then varied geometries can be formed, but additional time, materials, and cost are required
Solution Approach 1:
The patent incorporates cooling channels and fluid pathways directly into the electrode design before the EDM/ECM process begins. This preliminary integration of cooling features eliminates the need for subsequent machining operations to create these channels, reducing production time and material waste while maintaining the ability to form varied geometries in the extrusion die
Solution Approach 2:
The patent combines multiple functions into the electrode design: the electrode itself, the cooling channels, and the pattern formation features are all integrated into a single component. This merging reduces the number of separate manufacturing steps required, improving productivity while maintaining geometric versatility
3Adaptability or versatility
If plunge EDM or ECM is used to form extrusion dies, then complex patterns can be formed, but defects and inefficiencies occur due to specially configured electrodes
Solution Approach 1:
The patent optimizes electrode material parameters by using copper-tungsten composite materials with specific compositions (e.g., 60-40 wt% Cu-W, 70-30 wt% Cu-W). These parameter changes improve thermal conductivity and electrical properties, reducing defects during EDM/ECM while enabling complex pattern formation. The material composition is specifically tailored to match the workpiece material for minimal heat-affected zone and reduced defects
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for rapid and cost-effective production of electrodes with complex geometries, reducing surface roughness and minimizing defects, enabling the formation of entire extrusion die faces with precise patterns in a single operation.
Implementation Method 1
fusing the layer of powder using a laser to apply a laser energy of about 1 to about 10 J/mm2 to the layer of powder
Implementation Method 2
fusing the layer of powder using a laser to apply a laser energy of about 1 to about 10 J/mm2 to the layer of powder
Implementation Method 3
the electrode is comprised of an interconnected network of tungsten infiltrated by copper formed by the series of layers fused together
Data Source
AI summary
Methods for forming an electrode for use in forming a honeycomb extrusion die. The method includes forming, by means of an additive manufacturing process, an electrode includes a base having a web extending from the base. The web defines a matrix of cellular openings. The method further includes forming a secondary electrode having a plurality of pins. The plurality of pins are shaped and arranged so as to mate with the matrix of cellular openings defined by the web of the electrode. The method further includes machining the electrode using the secondary electrode to smooth surfaces of the electrode formed by the additive manufacturing process.